Golf ball which includes fast-chemical-reaction-produced component and method of making same

ABSTRACT

Disclosed herein is a golf ball comprising fast-chemical-reaction-produced component, such as a component which comprises a reaction injection molded polyurethane material. The golf ball has excellent light stability. Also disclosed is a method making a golf ball by forming a cover component of the ball by mixing two or more reactants that react and form a reaction product with a flex modulus of from about 1 to about 310 kpsi in a reaction time of about 5 minutes or less, the component having a thickness of at least 0.01 inches and a demold time of 10 minutes or less.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 11/475,788, filed on Jun. 27, 2006, which is acontinuation of U.S. patent application Ser. No. 10/905,913, filed onJan. 26, 2005, now U.S. Pat. No. 7,244,196.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates generally to golf balls, and more particularly togolf balls that contain a fast-chemical-reaction-produced component,such as a core and/or cover layer.

2. Description of the Related Art

Golf balls comprise, in general, three types. The first type is amulti-piece wound ball wherein a vulcanized rubber thread is wound undertension around a solid or semi-solid core, and thereafter enclosed in asingle or multi-layer covering of a tough, protective material. A secondtype of a golf ball is a one-piece ball formed from a solid mass ofresilient material that has been cured to develop the necessary degreeof hardness to provide utility. One-piece molded balls do not have asecond enclosing cover. A third type of ball is a multi-piece non-woundball which includes a liquid, gel or solid core of one or more layersand a cover having one or more layers formed over the core.

Conventional golf ball covers have been made of ionomer, balata, andslow-reacting, thermoset polyurethane. When polyurethane covers are madeby conventional methods, such as by casting, a substantial amount oftime and energy are required, thus resulting in relatively high cost.

It would be useful to develop a golf ball containing afast-chemical-reaction-produced component, such as at least one core orcover layer, particularly one which contains polyurethane, polyurea,epoxy and/or unsaturated polyester, and which has excellent lightstability and physical properties.

BRIEF SUMMARY OF THE INVENTION

An object of the invention is to produce a golf ball having apolyurethane cover which is formed by a fast chemical reaction. The golfball cover comprises a light stable, aliphatic-based polyurethanecomponent which is formed by reaction injection molding. The golf ballhas physical properties, such as scuff and cut resistance, that arecomparable to aromatic-based polyurethane covers.

Yet another object of the invention is to provide a method of making agolf ball of the type described above.

A preferred form of the invention is a multi-piece golf ball having acover layer comprising a reaction injection molded material comprisingpolyurethane/polyurea. The reaction injection molded material ispreferably an aliphatic-based material. The golf ball cover preferablyhas a Shore B hardness in the range of from about 20 to about 95, morepreferably from about 30 to about 75, and a flex modulus in the range of1 to about 310 kpsi, and more preferably from about 5 to about 100 kpsi.The golf ball has improved scuff and cut resistance and superior lightfastness and weathering over golf ball covers comprising aromatic basedpolyurethane/polyurea materials.

Another preferred form of the invention is a process for producing agolf ball including the step of reaction injection molding apolyurethane/polyurea material to form a cover layer of the ball.

Yet another preferred form of the invention is a process for producing agolf ball comprising (a) forming a core, (b) covering the core, and (c)coating and adding indicia to the covered ball, wherein step (b)comprises reaction injection molding of a polyurethane and/or polyureamaterial.

The golf ball of the invention can include, in the cover, opticalbrighteners, white pigment, UV stabilizers, antioxidants, etc. The coverand/or core may further include fillers such as TiO₂, glass, metal, andother fillers described below. Other objects of the invention willbecome apparent from the specification, drawings and claims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a first embodiment of a golf ball having a cover formedaccording to a reaction injection molded (RIM) process according to theinvention.

FIG. 2 is a second embodiment of a golf ball formed according to areaction injection molded (RIM) process according to the invention.

FIG. 3 is a third embodiment of a golf ball formed according to areaction injection molded (RIM) process according to the invention.

FIG. 4 is a process flow diagram which schematically depicts a reactioninjection molding process according to the invention.

FIG. 5 schematically shows a mold for reaction injection molding a golfball cover according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is a golf ball in which a cover layer is afast-chemical-reaction-produced component. This component comprises atleast one material selected from the group consisting of polyurethane,polyurea, polyurethane ionomer, epoxy, and unsaturated polyesters, andpreferably comprises polyurethane. Preferably, the polyurethane is analiphatic-based polyurethane. The invention also includes a method ofproducing a golf ball which contains a fast-chemical-reaction-producedcomponent. A golf ball cover layer formed according to the inventionpreferably has a flex modulus in the range of from about 1 to about 310kpsi, a Shore B hardness in the range of from about 20 to about 95, andgood light fastness and weathering, good scuff resistance and good cutresistance. As used herein, “polyurethane and/or polyurea” is expressedas “polyurethane/polyurea”. Reaction injection molding covers for golfballs offers numerous advantages over conventional slow-reactiveprocesses for producing golf ball covers. The RIM process producesmolded covers in a mold release or demold time of 10 minutes or less,preferably 2 minutes or less, and most preferably in 1 minute or less.The RIM process also results in the formation of a reaction product,formed by mixing two or more reactants together, that exhibits areaction time of about 2 minutes or less, preferably 1 minute or less,more preferably 30 seconds or less, and most preferably about 15 secondsor less. An excellent finish can also be produced on the ball.

The term “demold time” generally refers to the mold release time, whichis the time span from the mixing of the components until the earliestpossible time at which the part may be removed from the mold. At thattime of removal, the part is said to exhibit sufficient “greenstrength”. The term “reaction time” generally refers to the setting timeor curing time, which is the time span from the beginning of mixinguntil the time at which the product no longer flows. Further descriptionof the terms setting time and mold release time are provided in the“Polyurethane Handbook,” edited by Günter Oertel, Second Edition, ISBN1-56990-157-0, herein incorporated by reference.

The RIM process is particularly effective when recycled polyurethane orother polymer resin, or materials derived by recycling polyurethane orother polymer resin, are incorporated into the product. The process mayinclude the step of recycling at least a portion of the reactionproduct, preferably by glycolysis. From about 5% to about 100% of thepolyurethane/polyurea formed from the reactants used to form particularcomponents can be obtained from recycled polyurethane/polyurea.

As indicated above, the fast-chemical-reaction-produced component ispreferably a cover layer of the ball, although other layers, such as amantle layer, a core layer, and/or a core can also be produced. When apolyurethane cover is formed according to the invention, and is thencovered with a polyurethane topcoat, excellent adhesion can be obtained.The adhesion in this case is better than adhesion of a polyurethanecoating to an ionomeric cover. This improved adhesion can result in theuse of a thinner top coat, the elimination of a primer coat, and the useof a greater variety of golf ball printing inks beneath the top coat.These include but are not limited to typical inks such as one componentpolyurethane inks and two component polyurethane inks.

The preferred method of forming a fast-chemical-reaction-producedcomponent for a golf ball according to the invention is by reactioninjection molding (RIM). RIM is a process by which highly reactiveliquids are injected into a closed mold, mixed usually by impingementand/or mechanical mixing in an in-line device such as a “peanut mixer”,where they polymerize primarily in the mold to form a coherent,one-piece molded article. The RIM processes usually involve a rapidreaction between one or more reactive components such as polyether—orpolyester—polyol, polyamine, or other material with an active hydrogen,and one or more isocyanate—containing constituents, often in thepresence of a catalyst. The constituents are stored in separate tanksprior to molding and may be first mixed in a mix head upstream of a moldand then injected into the mold. The liquid streams are metered in thedesired weight to weight ratio and fed into an impingement mix head,with mixing occurring under high pressure (for example, at about 1500 toabout 3000 psi). The liquid streams impinge upon each other in themixing chamber of the mix head and the mixture is injected into themold. One of the liquid streams typically contains a catalyst for thereaction. The constituents react rapidly after mixing to gel and formpolyurethane polymers. Polyureas, epoxies, and various unsaturatedpolyesters also can be molded by RIM.

RIM differs from non-reaction injection molding in a number of ways. Themain distinction is that in RIM a chemical reaction takes place in themold to transform a monomer or adducts to polymers and the componentsare in liquid form. Thus, a RIM mold need not be made to withstand thepressures which occur in a conventional injection molding. In contrast,injection molding is conducted at high molding pressures in the moldcavity by melting a solid resin and conveying it into a mold, with themolten resin often being at about 150 to about 350° C. At this elevatedtemperature, the viscosity of the molten resin usually is in the rangeof about 50,000 to about 1,000,000 centipoise, and is typically around200,000 centipoise. In an injection molding process, the solidificationof the resins occurs after about 10-90 seconds, depending upon the sizeof the molded product, the temperature and heat transfer conditions, andthe hardness of the injection molded material. Subsequently, the moldedproduct is removed from the mold. There is no significant chemicalreaction taking place in an injection molding process when thethermoplastic resin is introduced into the mold. In contrast, in a RIMprocess, the chemical reaction typically takes place in less than abouttwo minutes, preferably in under one minute, and in many cases in about30 seconds or less.

If plastic products are produced by combining components that arepreformed to some extent, subsequent failure can occur at a location onthe cover which is along the seam or parting line of the mold. Failurecan occur at this location because this interfacial region isintrinsically different from the remainder of the cover layer and can beweaker or more stressed. The present invention is believed to providefor improved durability of a golf ball cover layer by providing auniform or “seamless” cover in which the properties of the covermaterial in the region along the parting line are generally the same asthe properties of the cover material at other locations on the cover,including at the poles. The improvement in durability is believed to bea result of the fact that the reaction mixture is distributed uniformlyinto a closed mold. This uniform distribution of the injected materialssignificantly reduces and/or eliminates knit-lines and other moldingdeficiencies which can be caused by temperature difference and/orreaction difference in the injected materials. The process of theinvention results in generally uniform molecular structure, density andstress distribution as compared to conventional injection-moldingprocesses.

The fast-chemical-reaction-produced component preferably has a flexmodulus of from about 1 to about 310 kpsi, more preferably from about 5to about 100 kpsi, and even more preferably 5 to about 70 kpsi. The corecan be one piece or multi-layer, each layer can be either foamed orunfoamed, and density adjusting fillers, including metals, can be used.The cover of the ball can be harder or softer than any particular corelayer, mantle layer or inner cover layer.

The fast-chemical-reaction-produced component can incorporate suitableadditives and/or fillers as known in the golf ball art. In an outercover layer, pigments or dyes, accelerators and UV stabilizers can beadded. Furthermore, compatible polymeric materials can be added. Forexample, when the component comprises polyurethane and/or polyurea, suchpolymeric materials include polyurethane ionomers, polyamides, and thelike.

A golf ball outer cover layer formed from afast-chemical-reaction-produced material according to the presentinvention typically contains 0 to about 20 weight percent of fillermaterial, more preferably from about 1 to about 10 weight percent, andmost preferably from about 1 to about 5 weight percent.

Catalysts can be added to the RIM polyurethane system starting materialsas long as the catalysts generally do not react with the constituentwith which they are combined. Suitable catalysts include those that areknown to be useful with polyurethanes and polyureas. Examples ofcatalysts are those well known in the art of polyurethanes, such as tin,zinc and zirconium catalysts, as well as amine catalysts. The tin, zincor zirconium catalyst preferably comprises at least one member selectedfrom the group consisting of a zirconium complex, dibutyl tin dilaurate,dibutyl acetylacetonate, dibutyl tin dibutoxide, dibutyl tin sulphide,dibutyl tin di-2-ethylhexanoate, dibutyl tin (IV) diacetate, dialkyltin(IV) oxide, tributyl tin laurylmercaptate, dibutyl tin dichloride,organo lead, tetrabutyl titanate, tertiary amines, mercaptides, stannousoctoate, potassium octoate, zinc octoate, diaza compounds, and potassiumacetate. Examples of amine catalysts include, but are not limited to,N,N,N′-trimethyl-N-hydroxyethyl-bisaminoethyl ether;N,N-bis(3-dimethylaminopropyl)-N-isopropanol amine;N-(3-dimethylaminopropyl)-N,N-diisopropanolamine;N,N-dimethylethanolamine; and 2-(2-dimethylaminoethoxy)ethanol. Thequantity of catalyst will depend upon the type of catalyst, polyol, andpolyisocyanate used, as well as the curing temperature and desiredcuring time and other factors. Generally, the amount of catalyst used isfrom about 0.005 to 0.5 weight percent. Two or more different catalystsmay also be used if desired.

The reaction mixture viscosity should be sufficiently low to ensure thatthe empty space in the mold is completely filled. The reactant materialsgenerally are preheated to about 80 to 200° F. before they are mixed. Inmost cases it is necessary to preheat the mold, for example, to about 80to 200° F., to ensure proper injection viscosity.

As indicated above, one or more cover layers of a golf ball can beformed from a fast-chemical-reaction-produced material according to thepresent invention.

Referring now to the drawings, and first to FIG. 1, a golf ball having acover comprising a RIM polyurethane is shown. The golf ball 10 includesa core 12 and a polyurethane cover 14 formed by RIM.

Referring now to FIG. 2, a golf ball having a core comprising a RIMpolyurethane is shown. The golf ball 20 has a RIM polyurethane core 22,and a RIM polyurethane cover 24.

Referring to FIG. 3, a multi-layer golf ball 30 is shown with a core 32,a mantle cover layer, and an outer cover layer comprising a RIMpolyurethane material. The core and/or mantle layer may comprise RIMpolyurethane or any other material known in the golf ball art.

Referring next to FIG. 4, a process flow diagram for forming a RIM coverof polyurethane is shown. Isocyanate from bulk storage is fed throughline 80 to an isocyanate tank 100. The isocyanate is heated to thedesired temperature, for example, to about 80 to about 200° F., bycirculating it through heat exchanger 82 via lines 84 and 86. Polyol,polyamine, or another compound with an active hydrogen atom is conveyedfrom bulk storage to a polyol tank 108 via line 88. The polyol is heatedto the desired temperature, for example, to about 80 to about 200° F.,by circulating it through heat exchanger 90 via lines 92 and 94. Drynitrogen gas is fed from nitrogen tank 96 to isocyanate tank 100 vialine 97 and to polyol tank 108 via line 98. Isocyanate is fed fromisocyanate tank 100 via line 102 through a metering cylinder or meteringpump 104 into recirculation mix head inlet line 106. Polyol is fed frompolyol tank 108 via line 110 through a metering cylinder or meteringpump 112 into a recirculation mix head inlet line 114. The recirculationmix head 116 receives isocyanate and polyol, mixes them, and providesfor them to be fed through nozzle 118 into injection mold 120. Theinjection mold 120 has a top mold 122 and a bottom mold 124. Coolantflows through cooling lines 126 in the top mold 122 and lines 128 in thebottom mold 124. The materials are kept under controlled temperatureconditions to insure that the desired reaction profile is maintained.

The polyol component typically contains additives, such as stabilizers,flow modifiers, catalysts, combustion modifiers, blowing agents,fillers, pigments, optical brighteners, and release agents to modifyphysical characteristics of the cover. Recycled polyurethane/polyureaalso can be added to the core. Polyurethane/polyurea constituentmolecules that were derived from recycled polyurethane can be added inthe polyol component.

Inside the mix head, injector nozzles impinge the isocyanate and polyolat ultra-high velocity to provide excellent mixing. Additional mixingpreferably is conducted using an aftermixer 130, which typically isconstructed inside the mold between the mix head and the mold cavity.

As is shown in FIG. 5, the mold includes a golf ball cavity chamber 132in which a spherical golf ball mold 134 with a dimpled, spherical moldcavity 136 is positioned. The aftermixer 130 can be a peanut aftermixer,as is shown in FIG. 5, or in some cases another suitable type, such as aheart, harp or dipper. An overflow channel 138 receives overflowmaterial from the golf ball mold 134 through a shallow vent 136. Coolingwater passages 138, which preferably are in a parallel flow arrangement,carry cooling water through the top mold 122 and the bottom mold 124.

The mold cavity contains retractable pins and is generally constructedin the same manner as a mold cavity used to injection mold athermoplastic, e.g., ionomeric golf ball cover. However, a fewdifferences when RIM is used are that tighter pin tolerances generallyare required, a lower mold temperature is used, and a lower injectionpressure is used. Also, the molds can be produced from lower strengthmaterial such as aluminum. The golf balls formed according to thepresent invention can be coated using a conventional two-component spraycoating or can be coated during the RIM process, for example, by usingan in-mold coating process.

One of the significant advantages of the RIM process according to theinvention is that polyurethane or other cover material can be recycledand used in golf ball cores. Recycling can be conducted by, for example,glycolysis. Typically, about 10 to 80% of the material which isinjection molded actually becomes part of the cover. The remaining 20 to90% is recycled.

Recycling of polyurethanes by glycolysis is known from, for example, RIMPart and Mold Design—Polyurethanes, 1995, Bayer Corp., Pittsburgh, Pa.Another significant advantage of the present invention is that becausereaction injection molding occurs at low temperatures and pressures (forexample, about 80 to about 200° F. and about 100 to 200 psi), thisprocess is particularly beneficial when a cover is to be molded over avery soft core. When higher pressures are used for molding over softcores, the cores “shut off” or deform and impede the flow of materialcausing uneven distribution of cover material.

Polyisocyanates represent the key substances in formingpolyurethane/polyurea. The general structure of polyisocyanates isR—(NCO)_(n), where n is at least two, and R is an aromatic or analiphatic group. The isocyanate groups (—N═C═O) that react with hydroxylgroups form a polyurethane, whereas isocyanate groups that react with anamine group form a polyurea. In the present invention, the isocyanategroups (i.e., the “iso” side) may react with the hydroxyl group, theamine group, or both (i.e., the “polyol” side), in order to formpolyurethane/polyurea.

In a preferred embodiment, the polyurethane component which of thepresent invention incorporates an aliphatic isocyanate or isocyanateprepolymer. Aliphatic isocyanates include, but are not limited to,hexamethylene diisocyanate (HDI); Methylene Dicyclohexyl Diisocyanate(H₁₂MDI); isophorone diisocyanate (IPDI); tetramethylene diisocyanate;octamethylene diisocyanate; decamethylene diisocyanate; dodecamethylenediisocyanate; tetradecamethylene diisocyanate; derivatives of lysinediisocyanate (LDI); tetramethylxylylene diisocyanate; trimethylhexanediisocyanate (TMDI) or tetramethylhexane diisocyanate; cycloaliphaticdiisocyanates such as 1,4-, 1,3- or 1,2-diisocyanatocyclohexane;4,4-di(isocyanatocyclohexyl)methane;1-isocyanato-3,3,5-trimethyl-5-(isocyanatomethyl)cyclohexane-(isophoronediisocyanate); 1,5-naphthalenediisocyanate (NDI) or 2,4- or2,6-diisocyanator-1-methylcyclohexane. Aliphatic isocyanates generallyexhibit good light fastness and UV stability, but are slower to reactand produce softer polymers than the aromatic isocyanates. Polyurethanesbased on an aliphatic diisocyanate can provide improved gloss retentionUV light stability, thermal stability hydrolytic stability.Additionally, TMXDI (META) aliphatic isocyanate has demonstratedfavorable toxicological properties. Furthermore, because it has a lowviscosity, it is usable with a wider range of diols (to polyurethane)and diamines (to polyureas). If TMXDI is used, it typically, but notnecessarily, is added as a direct replacement for some or all of theother aliphatic isocyanates in accordance with the suggestions of thesupplier. Because of slow reactivity of TMXDI, it may be useful ornecessary to use catalysts to have practical demolding times. Hardness,tensile strength and elongation can be adjusted by adding furthermaterials in accordance with the supplier's instructions. IPDI ispreferred in some cases due to its good impact resistance.

The polyol component is preferably a polyester or polyether basedprepolymer. Examples of polyester and polyether based prepolymersinclude, but are not limited to, PTMEG; PPG; PEG; and the like. Apreferred polyol is PTMEG, but the polyol choice depends on the desiredfinal properties, such as scuff and cut resistance.

The polyol component typically contains additives, such as stabilizers,flow modifiers, catalysts, combustion modifiers, blowing agents,fillers, pigments, optical brighteners, and release agents to modifyphysical characteristics of the cover. Polyurethane/polyurea constituentmolecules that were derived from recycled polyurethane can be added inthe polyol component.

Chain extenders may also be used with polyisocyanates to formpolyurethane/polyurea. Chain extenders lengthen the main chain ofpolyurethane/polyurea causing end-to-end attachments. Examples of chainextenders for use in forming polyurethane/polyurea include glycol chainextenders and amine chain extenders. Suitable glycol chain extendersinclude, but are not limited to, ethylene glycol; propylene glycol;butane glycol; pentane glycol; hexane glycol; benzene glycol; xyleneglycol; 1,4-butane diol; 1,3-butane diol; 2,3-dimethyl-2,3-butane diol;and dipropylene glycol. Suitable amine chain extenders include, but arenot limited to, tetramethyl-ethylenediamine; dimethylbenzylamine;diethylbenzylamine; pentamethyldiethylenetriamine; dimethylcyclohexylamine; tetramethyl-1,3-butanediamine; 1,2-dimethylimidazole;bis-(dimethylaminoethylether); 2-methylimidazole; andpentamethyldipropylenetriamine.

Golf ball cores also can be made using the materials and processes ofthe invention. To make a golf ball core using RIM polyurethane, the sameprocessing conditions are used as are described above with respect tocovers. One difference is, of course, that no retractor pins are neededin the mold. Furthermore, an undimpled, smaller mold is used. If,however, a one piece ball is desired, a dimpled mold would be used.Polyurethanes also can be used for cores.

Golf balls typically have indicia and/or logos stamped or formedthereon. Such indicia can be applied by printing using a material or asource of energetic particles after the ball core and/or cover have beenreaction-injection-molded according to the present invention. Printedindicia can be formed form a material such as ink, foil (for use in foiltransfer), etc. Indicia printed using a source of energetic particles orradiation can be applied by burning with a laser, burning with heat,directed electrons, or light, phototransformations of, e.g., UV ink,impingement by particles, impingement by electromagnetic radiation etc.Furthermore, the indicia can be applied in the same manner as an in-moldcoating, for example, by applying to the indicia to the surface of themold prior to molding of the cover.

Additional materials may also be added to the inner and outer coverlayer of the present invention as long as they do not substantiallyreduce the playability properties of the ball. Such materials includedyes and/or optical brighteners (for example, Ultramarine Blue™ sold byWhittaker, Clark, and Daniels of South Plainsfield, N.J.) (see U.S. Pat.No. 4,679,795); pigments such as titanium dioxide, zinc oxide, bariumsulfate and zinc sulfate; UV absorbers; antioxidants; antistatic agents;and stabilizers. Moreover, the cover compositions of the presentinvention may also contain softening agents such as those disclosed inU.S. Pat. Nos. 5,312,857 and 5,306,760, including plasticizers, metalstearates, processing acids, and the like, and reinforcing materialssuch as glass fibers and inorganic fillers, as long as the desiredproperties produced by the golf ball covers of the invention are notimpaired. The polyurethane which is selected for use as a golf ballcover preferably has a Shore B hardness of 20 to 95, and more preferably30 to 75. The polyurethane which is to be used for a cover layerpreferably has a flex modulus of from about 1 to about 310 kpsi, andmore preferably from about 5 to about 100 kpsi.

Non-limiting examples of suitable RIM systems for use in the presentinvention are Bayflex® elastomeric polyurethane RIM systems, Baydur® GSsolid polyurethane RIM systems, Prism (solid polyurethane RIM systems,all from Bayer Corp. (Pittsburgh, Pa.), SPECTRIM reaction moldablepolyurethane and polyurea systems from Dow Chemical USA (Midland,Mich.), including SPECTRIM MM 373-A (isocyanate) and 373-B (polyol), andElastolit SR systems from BASF (Parsippany, N.J.), and VIBRARIM systemsfrom Crompton Uniroyal Corporation (Middlebury, Conn.). Furtherpreferred examples are polyols, polyamines and isocyanates formed byprocesses for recycling polyurethanes and polyureas. Peroxides, such asMEK-peroxide and dicumyl peroxide can be used. Furthermore, catalysts oractivators such as cobalt octoate 6%, dibutyl tin dilaurate, and thelike, can be used.

The polyurethane prepolymer is preferably a polytetramethylene etherglycol terminated 4,4′-diphenylmethane diisocyanate-based polyurethaneprepolymers. Preferred polytetramethylene ether glycol terminated4,4′-diphenylmethane diisocyanate-based polyurethane prepolymers areavailable from Uniroyal Chemical Company of Middlebury, Conn., under thetradename VIBRATHANE®, and include VIBRATHANE® (B836, VIBRATHANE® B670,VIBRATHANE®B625. An alternative polyurethane prepolymer is an esterterminated 4,4′-diphenylmethane diisocyanate-based polyurethaneprepolymers such as VIBRATHANE® 8520, VIBRATHANE® 8007, VIBRATHANE® 8010and VIBRATHANE® 6012.

The ratio of the polyurethane prepolymer to curative is determined bythe nitrogen-carbon-oxygen group (“NCO”) content of the polyurethaneprepolymer. For example, the NCO group content of the polytetramethyleneether glycol terminated 4,4′-diphenylmethane diisocyanate-basedpolyurethane prepolymer is preferably in the range of 12.0% to 18.0%,more preferably in the range of 14.0% to 16.5%, and most preferably16.0%. The NCO content of the ester terminated 4,4′-diphenylmethanediisocyanate-based polyurethane prepolymer is preferably range of 12.0%to 18.0%, more preferably in the range of 14.0% to 16.5%, and mostpreferably 16.0%.

The core 32 of the golf ball 30 is preferably a single solid core suchas disclosed in U.S. Pat. No. 6,612,940, assigned to Callaway GolfCompany and which pertinent parts are hereby incorporated by reference,or such as disclosed in U.S. Pat. No. 6,465,546, also assigned toCallaway Golf Company and which pertinent parts are hereby incorporatedby reference. However, alternative embodiments have a non-solid ormultiple cores such as disclosed in U.S. Pat. No. 6,663,509, whichpertinent parts are hereby incorporated by reference. In a preferredembodiment, the finished core 12 has a diameter of about 1.35 to about1.64 inches for a golf ball 10 having an outer diameter of 1.68 inches.The core weight is preferably maintained in the range of about 32 toabout 40 g. The core PGA compression is preferably maintained in therange of about 50 to 90, and most preferably about 55 to 80.

As used herein, the term “PGA compression” is defined as follows:

PGA compression value=180−Riehle compression value

The Riehle compression value is the amount of deformation of a golf ballin inches under a static load of 200 pounds, multiplied by 1000.Accordingly, for a deformation of 0.095 inches under a load of 200pounds, the Riehle compression value is 95 and the PGA compression valueis 85.

A boundary layer 34 is preferably composed of a thermoplastic material.Suitable thermoplastic materials for the boundary layer 34 include:HYTREL® and/or HYLENE® products from DuPont, Wilmington, Del.; PEBAX®products from Elf Atochem, Philadelphia, Pa.; SURLYN® products fromDuPont; and/or ESCOR® or IOTEK® products from Exxon Chemical, Houston,Tex.

In a preferred embodiment of the golf ball 30, the boundary layer 34comprises a high acid (i.e. greater than 16 weight percent acid) ionomerresin or a blend of one or more high acid ionomers and one or more lowacid ionomers (i.e. 16 weight percent acid or less)

The boundary layer 34 compositions of the embodiments described hereinmay include the high acid ionomers such as those developed by E. I.DuPont de Nemours & Company under the SURLYN brand, and by ExxonCorporation under the ESCOR or IOTEK brands, or blends thereof. Examplesof compositions which may be used as the boundary layer 34 herein areset forth in detail in U.S. Pat. No. 5,688,869, which is incorporatedherein by reference. The boundary layer 34 high acid ionomercompositions are not limited in any way to those compositions set forthin said patent. Those compositions are incorporated herein by way ofexamples only.

The high acid ionomers which may be suitable for use in formulating theboundary layer 34 compositions are ionic copolymers which are the metal(such as sodium, zinc, magnesium, etc.) salts of the reaction product ofan olefin having from about 2 to 8 carbon atoms and an unsaturatedmonocarboxylic acid having from about 3 to 8 carbon atoms. Preferably,the ionomeric resins are copolymers of ethylene and either acrylic ormethacrylic acid. In some circumstances, an additional comonomer such asan acrylate ester (for example, iso- or n-butylacrylate, etc.) can alsobe included to produce a softer terpolymer. The carboxylic acid groupsof the copolymer are partially neutralized (for example, approximately10-100%, preferably 30-70%) by the metal ions. Each of the high acidionomer resins which may be included in the inner layer covercompositions of the invention contains greater than 16% by weight of acarboxylic acid, preferably from about 17% to about 25% by weight of acarboxylic acid, more preferably from about 18.5% to about 21.5% byweight of a carboxylic acid. Examples of the high acid methacrylic acidbased ionomers found suitable for use in accordance with this inventioninclude, but are not limited to, SURLYN 8220 and 8240 (both formerlyknown as forms of SURLYN AD-8422), SURLYN 9220 (zinc cation), SURLYNSEP-503-1 (zinc cation), and SURLYN SEP-503-2 (magnesium cation).According to DuPont, all of these ionomers contain from about 18.5 toabout 21.5% by weight methacrylic acid. Examples of the high acidacrylic acid based ionomers suitable for use in the present inventionalso include, but are not limited to, the high acid ethylene acrylicacid ionomers produced by Exxon such as Ex 1001, 1002, 959, 960, 989,990, 1003, 1004, 993, and 994. In this regard, ESCOR or IOTEK 959 is asodium ion neutralized ethylene-acrylic neutralized ethylene-acrylicacid copolymer. According to Exxon, IOTEKS 959 and 960 contain fromabout 19.0 to about 21.0% by weight acrylic acid with approximately 30to about 70 percent of the acid groups neutralized with sodium and zincions, respectively.

Furthermore, as a result of the previous development by the assignee ofthis application of a number of high acid ionomers neutralized tovarious extents by several different types of metal cations, such as bymanganese, lithium, potassium, calcium and nickel cations, several highacid ionomers and/or high acid ionomer blends besides sodium, zinc andmagnesium high acid ionomers or ionomer blends are also available forgolf ball cover production. It has been found that these additionalcation neutralized high acid ionomer blends produce boundary layer 34compositions exhibiting enhanced hardness and resilience due tosynergies which occur during processing. Consequently, these metalcation neutralized high acid ionomer resins can be blended to producesubstantially higher C.O.R.'s than those produced by the low acidionomer boundary layer 34 compositions presently commercially available.More particularly, several metal cation neutralized high acid ionomerresins have been produced by the assignee of this invention byneutralizing, to various extents, high acid copolymers of analpha-olefin and an alpha, beta-unsaturated carboxylic acid with a widevariety of different metal cation salts. This discovery is the subjectmatter of U.S. Pat. No. 5,688,869, incorporated herein by reference. Ithas been found that numerous metal cation neutralized high acid ionomerresins can be obtained by reacting a high acid copolymer (i.e. acopolymer containing greater than 16% by weight acid, preferably fromabout 17 to about 25 weight percent acid, and more preferably about 20weight percent acid), with a metal cation salt capable of ionizing orneutralizing the copolymer to the extent desired (for example, fromabout 10% to 90%).

The base copolymer is made up of greater than 16% by weight of an alpha,beta-unsaturated carboxylic acid and an alpha-olefin. Optionally, asoftening comonomer can be included in the copolymer. Generally, thealpha-olefin has from 2 to 10 carbon atoms and is preferably ethylene,and the unsaturated carboxylic acid is a carboxylic acid having fromabout 3 to 8 carbons. Examples of such acids include acrylic acid,methacrylic acid, ethacrylic acid, chloroacrylic acid, crotonic acid,maleic acid, fumaric acid, and itaconic acid, with acrylic acid beingpreferred.

The softening comonomer that can be optionally included in the boundarylayer 34 of the golf ball of the invention may be selected from thegroup consisting of vinyl esters of aliphatic carboxylic acids whereinthe acids have 2 to 10 carbon atoms, vinyl ethers wherein the alkylgroups contain 1 to 10 carbon atoms, and alkyl acrylates ormethacrylates wherein the alkyl group contains 1 to 10 carbon atoms.Suitable softening comonomers include vinyl acetate, methyl acrylate,methyl methacrylate, ethyl acrylate, ethyl methacrylate, butyl acrylate,butyl methacrylate, or the like.

Consequently, examples of a number of copolymers suitable for use toproduce the high acid ionomers included in the present inventioninclude, but are not limited to, high acid embodiments of anethylene/acrylic acid copolymer, an ethylene/methacrylic acid copolymer,an ethylene/itaconic acid copolymer, an ethylene/maleic acid copolymer,an ethylene/methacrylic acid/vinyl acetate copolymer, anethylene/acrylic acid/vinyl alcohol copolymer, etc. The base copolymerbroadly contains greater than 16% by weight unsaturated carboxylic acid,from about 39 to about 83% by weight ethylene and from 0 to about 40% byweight of a softening comonomer. Preferably, the copolymer containsabout 20% by weight unsaturated carboxylic acid and about 80% by weightethylene. Most preferably, the copolymer contains about 20% acrylic acidwith the remainder being ethylene.

The boundary layer 34 compositions may include the low acid ionomerssuch as those developed and sold by E. I. DuPont de Nemours & Companyunder the SURLYN and by Exxon Corporation under the brands ESCOR andIOTEK, ionomers made in-situ, or blends thereof.

Another embodiment of the boundary layer 34 comprises a non-ionomericthermoplastic material or thermoset material. Suitable non-ionomericmaterials include, but are not limited to, metallocene catalyzedpolyolefins or polyamides, polyamide/ionomer blends, polyphenyleneether/ionomer blends, etc., which preferably have a Shore D hardness ofat least 60 (or a Shore C hardness of at least about 90) and a flexmodulus of greater than about 30,000 psi, preferably greater than about50,000 psi, or other hardness and flex modulus values which arecomparable to the properties of the ionomers described above. Othersuitable materials include but are not limited to, thermoplastic orthermosetting polyurethanes, thermoplastic block polyesters, forexample, a polyester elastomer such as that marketed by DuPont under thebrand HYTREL, or thermoplastic block polyamides, for example, apolyether amide such as that marketed by Elf Atochem S. A. under thebrand PEBEX, a blend of two or more non-ionomeric thermoplasticelastomers, or a blend of one or more ionomers and one or morenon-ionomeric thermoplastic elastomers. These materials can be blendedwith the ionomers described above in order to reduce cost relative tothe use of higher quantities of ionomer.

The Shore D hardness of the boundary layer 34 preferably ranges from 40to 75, as measured according to ASTM D-2290. In a most preferredembodiment, the boundary layer 34 has a Shore D hardness in the range of50-65. One reason for preferring a boundary layer 34 with a Shore Dhardness of 75 or lower is to improve the feel of the resultant golfball. It is also preferred that the boundary layer 34 is composed of ablend of SURLYN® ionomer resins. One preferred formulation for theboundary layer 34 has 25-50 weight percent SURLYN 8150, 25-50 weightpercent SURLYN 9150, and 25-50 weight percent SURLYN 6320. Anotherformulation for the boundary layer 14 has 25-75 weight percent SURLYN9150, and 25-75 weight percent SURLYN 6320. Those skilled in thepertinent art will recognize that other ionomers may be utilized for theoptional boundary layer 34 without departing from the scope and spiritof the present invention. The Shore D hardness of the boundary layer 34is preferably 50 to 75, more preferably from 55-65 Shore D, and mostpreferably 58-63 Shore D, as measured according to ASTM-D2240.

The polyurethane material of the present invention preferably has aShore D hardness ranging from 30 to 60 as measured according toASTM-D2240, more preferably 40 to 55 Shore D, and most preferably 50Shore D.

As shown in FIG. 3, the preferred construction of a golf ball 30utilizing the fast-chemical reaction produced material of the presentinvention is a three-piece solid golf ball having a solid polybutadienecore 32, a boundary layer 34 composed of a blend of ionomers, and acover 36 composed of the polyurethane material of the present invention.The core 32 is preferably compression molded, the boundary layer 34 ispreferably injection molded, and the cover 16 is reaction injectionmolded. The golf ball 30 may be finished with one or two layers of abase white coating, a clear coating and an indicia.

The thickness of the cover 36 preferably ranges from 0.010 inch to 0.070inch, more preferably ranges from 0.014 inch to 0.050 inch, evenpreferably ranges from 0.015 inch to 0.044 inch, most preferably rangesfrom 0.020 inch to 0.030 inch, and is most preferably 0.025 inch. Theboundary layer 34 is preferably injection molded and preferably rangesin thickness from 0.040 inch to 0.090 inch, more preferably from 0.045inch to 0.070 inch, and most preferably from 0.050 inch to 0.060 inch.The boundary layer 34 may also be compression molded from half shells.The core 32 preferably has a diameter of between 1.35 inches and 1.60inches, more preferably between 1.45 inches and 1.55 inches, and mostpreferably 1.49 inches. The core 32 preferably has a PGA compressionranging from 70-110 points, and most preferably 100 points. A moredetailed description of a construction and performance properties of agolf ball utilizing the polyurethane material of the present inventionis set forth in U.S. Pat. No. 6,443,858, for a Golf Ball With A HighCoefficient Of Restitution, issued on Sep. 2, 2002, assigned to CallawayGolf Company, and U.S. Pat. No. 6,478,697 for a Golf Ball With A HighCoefficient Of Restitution, filed on Nov. 12, 2002, assigned to CallawayGolf Company, both of which are hereby incorporated by reference intheir entireties.

The Shore D hardness of each of the golf balls 10, 20 and 30, asmeasured on the golf ball, is preferably between 30 Shore D points to 75Shore D points, and most preferably between 50 Shore D points and 65Shore D points. The hardness is measured using an Instron Shore DHardness measurement device wherein the golf ball is placed within aholder and the pin is lowered to the surface to measure the hardness.The average of five measurements is used in calculating the ballhardness. The ball hardness is preferably measured on a land area of thecover 14, 24 and 36. The preferred overall diameter of the golf ball 10,20 or 30 is approximately 1.68 inches, and the preferred mass isapproximately 45.5 grams. However, those skilled in the pertinent artwill recognize that the diameter of the golf ball 10, 20 or 30 may besmaller (e.g. 1.65 inches) or larger (e.g. 1.70 inches) withoutdeparting from the scope and spirit of the present invention. Further,the mass may also vary without departing from the scope and spirit ofthe present invention.

The surface geometry of each of the golf balls 10, 20 and 30 ispreferably a conventional dimple pattern such as disclosed in U.S. Pat.No. 6,213,898 for a Golf Ball With An Aerodynamic Surface On APolyurethane Cover, which pertinent parts are hereby incorporated byreference. Alternatively, the surface geometry of each of the golf balls10, 20 and 30 may have a non-dimple pattern such as disclosed in U.S.Pat. No. 6,290,615 filed on Nov. 18, 1999 for A Golf Ball Having Tubularlattice Pattern, which pertinent parts are hereby incorporated byreference.

EXAMPLES

The following examples are included for purposes of illustration and arenot intended to be limiting.

Example 1

Golf balls having cores and covers were produced using various aliphaticand aromatic polyurethane RIM systems. The aliphatic RIM systemscomprised an aliphatic polyol and an H₁₂MDI/PTMEG prepolymer. Thearomatic systems comprised MDI/PTMEG-based prepolymers and PTMEG/MOCAcuratives. (Note: MOCA is 4,4′-methylene-bis-(ortho-chloroaniline, acuring agent for polyurethane elastomers.) The balls were tested tomeasure light stability, cut, scuff and Shore C and Shore D hardness.Two controls, a Strata Tour Ultimate and a Titleist ProV1 were alsomeasured. The results follow in Table 2.

TABLE 1 Shore Weather Type Scuff Cut Oven C, D Test Aromatic SystemControl 1.6 2 Above 46, 34 Fail Aromatic Ave. Harder 1.8 2 Above 40, 29Fail Ave. Harder, 1.7 2 Above 40, 28 Fail more Ave. resilient AliphaticSystem Control 1.8 2 Above 52, 34 Pass Aliphatic Ave. Harder 2.0 2 Above50, 33 Pass Ave. Harder, 2.0 2 Above 61, 39 Pass more Ave. resilientControls Type Scuff Cut Oven Weather Test Tour Ultimate 3.0 3 Good PassProV1 2.0 1 Excellent Pass

Table 1 shows that golf ball covers made with aliphatic RIM systems haveproperties similar to those of aromatic RIM systems as well asthermoplastic polyurethanes and cast polyurethanes, as exhibited by thecommercially available samples. The aliphatic RIM covers passed theweather test as well.

Example 2

Additional two-piece and three-piece golf balls having were producedusing various aliphatic and aromatic polyurethane RIM systems. Thealiphatic RIM systems comprised an aliphatic polyol and an H₁₂MDI/PTMEGprepolymer. The aromatic systems comprised MDI/MEG-based prepolymers andPTMEG/MOCA curatives. The balls were tested to measure light stability,cut, scuff and Shore C hardness. Two controls, a Strata Tour Ultimateand a Titleist ProV1 were also measured. The results follow in Table 3.

TABLE 2 Shore Weather Type Scuff Cut Oven C Test Aromatic System 3 piece2.5 2 Good 72 Fail 3 piece 3.0 1 Good 64 Fail 3 piece 3.3 1 Good 75 FailAliphatic System 2 piece 1.7 1 Exc. 67 Pass 3 piece 1.7 2 Exc. 69 Pass 3piece 2.0 2 Exc. 75 Pass 3 piece 2.3 1 Exc. 69 Pass Controls Type ScuffCut Oven Weather Test Tour Ultimate 3.0 3 Good Pass ProV1 3.1 2Excellent Pass RIM 3.1 2 Excellent Pass

The above results in Table 2 also show that the golf balls having a RIMpolyurethane cover formed from an aliphatic based polyurethane/polyureaexhibited scuff and cut results as good as commercially available golfballs and aromatic based polyurethane/polyurea covered golf balls.Additionally, the golf balls of the invention having aliphatic basedpolyurethane/polyurea covers exhibited better light stability asexhibited by the weather test.

DEFINITIONS Fillers

In a particularly preferred form of the invention, at least one layer ofthe golf ball contains at least one part by weight of a filler. Fillerspreferably are used to adjust the density, flex modulus, mold release,and/or melt flow index of a layer. More preferably, at least when thefiller is for adjustment of density or flex modulus of a layer, it ispresent in an amount of at least 2 parts by weight based upon 100 partsby weight of the layer composition. With some fillers, up to about 200parts by weight probably can be used.

A density adjusting filler according to the invention preferably is afiller which has a specific gravity which is at least 0.05 and morepreferably at least 0.1 higher or lower than the specific gravity of thelayer composition. Particularly preferred density adjusting fillers havespecific gravities which are higher than the specific gravity of theresin composition by 0.2 or more, even more preferably by 2.0 or more.

A flex modulus adjusting filler according to the invention is a fillerwhich, when used in an amount of from about 1 to about 100 parts byweight based upon 100 parts by weight of resin composition, will raiseor lower the flex modulus (ASTM D-790) of the resin composition by atleast 1% and preferably at least 5% as compared to the flex modulus ofthe resin composition without the inclusion of the flex modulusadjusting filler.

A mold release adjusting filler is a filler which allows for the easierremoval of a part from a mold, and eliminates or reduces the need forexternal release agents which otherwise could be applied to the mold. Amold release adjusting filler typically is used in an amount of up toabout 2 weight percent based upon the total weight of the layer.

A melt flow index adjusting filler is a filler which increases ordecreases the melt flow, or ease of processing of the composition.

The layers may contain coupling agents that increase adhesion ofmaterials within a particular layer e.g. to couple a filler to a resincomposition, or between adjacent layers. Non-limiting examples ofcoupling agents include titanates, zirconates and silanes. Couplingagents typically are used in amounts of from about 0.1 to about 2 weightpercent based upon the total weight of the composition in which thecoupling agent is included.

A density adjusting filler is used to control the moment of inertia, andthus the initial spin rate of the ball and spin decay. The addition inone or more layers, and particularly in the outer cover layer of afiller with a lower specific gravity than the resin composition resultsin a decrease in moment of inertia and a higher initial spin rate thanwould result if no filler were used. The addition in one or more of thecover layers, and particularly in the outer cover layer of a filler witha higher specific gravity than the resin composition, results in anincrease in moment of inertia and a lower initial spin rate. Highspecific gravity fillers are preferred as less volume is used to achievethe desired inner cover total weight. Nonreinforcing fillers are alsopreferred as they have minimal effect on COR. Preferably, the fillerdoes not chemically react with the resin composition to a substantialdegree, although some reaction may occur when, for example, zinc oxideis used in a shell layer which contains some ionomer.

The density-increasing fillers for use in the invention preferably havea specific gravity in the range of from about 1.0 to about 20. Thedensity-reducing fillers for use in the invention preferably have aspecific gravity of from about 0.06 to about 1.4, and more preferablyform about 0.06 to about 0.90. The flex modulus increasing fillers havea reinforcing or stiffening effect due to their morphology, theirinteraction with the resin, or their inherent physical properties. Theflex modulus reducing fillers have an opposite effect due to theirrelatively flexible properties compared to the matrix resin. The meltflow index increasing fillers have a flow enhancing effect due to theirrelatively high melt flow versus the matrix. The melt flow indexdecreasing fillers have an opposite effect due to their relatively lowmelt flow index versus the matrix.

Fillers which may be employed in layers other than the outer cover layermay be or are typically in a finely divided form, for example, in a sizegenerally less than about 20 mesh, preferably less than about 100 meshU.S. standard size, except for fibers and flock, which are generallyelongated. Flock and fiber sizes should be small enough to facilitateprocessing. Filler particle size will depend upon desired effect, cost,ease of addition, and dusting considerations. Examples of fillerssuitable for use include, but are not limited to, precipitated hydratedsilica, clay, talc, asbestos, glass fibers, aramid fibers, mica, calciummetasilicate, barium sulfate, zinc sulfide, lithopone, silicates,silicon carbide, diatomaceous earth, polyvinyl chloride, carbonates,metals, metal alloys, tungsten carbide, metal oxides, metal stearates,particulate carbonaceous materials, micro balloons, and combinationsthereof. All of fillers except for metal stearates would be expected toreduce the melt flow index of an injection molded cover layer. Theamount of filler employed is primarily a function of weight requirementsand distribution.

Scuff Resistance

The scuff resistance test was conducted in the manner described below.The balls that were tested were primed and top coated. A Titleist Vokey56° Wedge (256.12) was mounted in a mechanical swing machine. The clubswing speed used is 70 mph. After each hit, the clubface is brushedclean using a nylon bristled brush. A minimum of three samples of eachball were tested. Each ball was hit three times at three differentlocations so as not to overlap with other strikes. The details of theclub face are critical, and are as follows:

Groove width—0.026 inches

Groove depth—0.014 inches;

For each strike, a point value is assigned based on a scale from 0.0 to6.0 with 0.0 representing no visible mark from the strike and 6.0representing shredding of the material, with consideration given to apotential end user's perception of cover damage. After completing allstrikes, determine the average point value. This average point value, orrank, can be correlated to the chart below.

Scuff Test Ranking

Rank Average Point Value Excellent 0.0-1.0 Very Good 1.1-2.0 Good2.1-3.0 Fair 3.1-4.0 Borderline 4.1-5.0 Poor (unacceptable) 5.1-6.0

Cut Test

The cut test (off center cut) was performed as described below. An offcenter cut test was used as it more closely represents actual play. Theshear component of this blow makes the off-center cut test the mostsevere and most useful in determining the cut resistance of a covermaterial.

The cut performance test consists of cutting a minimum of three golfballs at least twice. Each cut is in a different location on the ball soas not to overlap other cuts. Cutting the samples directly on theequator should be avoided. The off-center cut test uses a guillotine tostrike the ball with a glancing blow and represents a mishit where theball might be topped or skulled. To perform the test, adjust the sampleholder to the appropriate position and place the golf ball in the sampleholder. Carefully lift the guillotine to the top of its stroke, makingsure not to hit the release switch on the left of the head. The headshould stay at the top by means of its clutch mechanism. Tap the releaseswitch on the left of the head to release the guillotine to strike theball. Rotate the ball for the next blow(s) making sure the subsequentstrike(s) will not overlap. Once all the samples have been cut, eachstrike is ranked according to the guidelines below. The cut ranking forthe sample set is represented by the average of all cuts. An overallranking of 3 or better is necessary for acceptable field durability.

DEFECT CHARACTER CUT RANK No Visible Marks 0 Barely Visible Lines 1Distinct Lines 2 Lines with few Wrinkles 3 Wrinkles and Minor Cuts 4Deep Cuts or Tearing 5

Weather Test

Golf balls are placed in a weatherometer, such as an Atlas Ci35A, 6500watt weatherometer, for 36 hours. They are exposed to constant light forthe duration of the test. After 36 hours, the golf balls are removed andthe covers are checked for light stability. If there is significantcolor change, the ball fails.

Oven Test

Golf balls were placed in an oven “soak” at about 70C overnight(approximately 16 hours). At the end of the test, the golf balls wereremoved and visually assessed to determine if the cover “melted” or not.The covers were rated as Excellent, Good, or Poor, depending on how muchthe cover melted or changed.

1. A golf ball comprising: a core; and a cover disposed about said core;wherein said cover comprises a fast reacting aliphatic-basedpolyurethane and/or polyurea material, wherein said fast reactingaliphatic-based polyurethane and/or polyurea material has a reactiontime of less than two minutes at processing conditions.
 2. The golf ballof claim 1, wherein said aliphatic-based polyurethane and/or polyureamaterial comprises the reaction product of an aliphatic diisocyanateprepolymer, an aliphatic polyol and a catalyst.
 3. The golf ball ofclaim 1, wherein the reaction time is less than fifteen seconds atprocessing conditions.
 4. The golf ball of claim 1, wherein thediisocyanate prepolymer is selected from the group consisting ofhexamethylene diisocyanate (HDI); methylene dicyclohexyl diisocyanate(H₁₂MDI); isophorone diisocyanate (IPDI); tetramethylene diisocyanate;octamethylene diisocyanate; decamethylene diisocyanate; dodecamethylenediisocyanate; tetradecamethylene diisocyanate; lysine diisocyanate(LDI); tetramethylxylylene diisocyanate; trimethylhexane diisocyanate(TMDI); tetramethylhexane diisocyanate; 1,4-diisocyanatocyclohexane;1,3-diisocyanatocyclohexane; 1,2-diisocyanatocyclohexane;4,4-di(isocyanatocyclohexyl)methane;1-isocyanato-3,3,5-trimethyl-5-(isocyanatomethyl)cyclohexane-(isophoronediisocyanate); 2,4-diisocyanator-1-methylcyclohexane;2,6-diisocyanato-1-methylcyclohexane; 1,5-naphthalenediisocyanate (NDI);and combinations and derivatives thereof.
 5. The golf ball of claim 4,wherein the diisocyanate is H₁₂MDI.
 6. A golf ball comprising: a core;and a cover formed over the core, the cover composed of a fast chemicalreaction material formed from reactants comprising 1,6,hexamethylene-diisocyanate and a polytetramethylene ether glycol;wherein the cover has a thickness ranging from 0.010 inch to 0.044 inch.7. The golf ball according to claim 6 further comprising at least oneboundary layer disposed between the core and the cover, and the boundarylayer is composed of a blend of ionomers.
 8. The golf ball according toclaim 6 wherein the core is a solid core composed of a polybutadienebased mixture.
 9. A golf ball comprising: a core comprising apolybutadiene mixture; a boundary layer formed over the core; and acover formed over the core, the cover composed of a fast chemicalreaction aliphatic polyurethane material formed from reactantscomprising 1,6, hexamethylene-diisocyanate and a polytetramethyleneether glycol;
 10. A golf ball comprising: a core comprising apolybutadiene mixture; a boundary layer formed over the core; and acover formed over the core, the cover composed of a fast chemicalreaction aliphatic polyurethane material formed from reactantscomprising a diisocyanate and a polyol blend, wherein the fast chemicalreaction aliphatic polyurethane material has a Shore D hardness rangingfrom 30 to 60 as measured according to ASTM-D2240, and a thicknessranging from 0.010 inch to 0.044 inch.
 11. A golf ball comprising: acore; and a cover formed over the core, the cover composed of a fastchemical reaction aliphatic polyurethane material formed from reactantscomprising a polytetramethylene ether glycol terminated4,4′-diphenylmethane diisocyanate polyurethane prepolymer and acurative; wherein the cover has an aerodynamic surface geometry thereon.12. The golf ball according to claim 11 further comprising at least oneboundary layer disposed between the core and the cover, wherein theboundary layer is composed of a blend of ionomers.
 13. A golf ballcomprising: a core comprising a polybutadiene mixture, the core having adiameter ranging from 1.35 inches to 1.64 inches and having a PGAcompression ranging from 50 to 90; a boundary layer formed over thecore, the boundary layer composed of a blend of ionomer materials, theboundary layer having a thickness ranging from 0.020 inch to 0.075 inch,the blend of ionomer materials having a Shore D hardness ranging from 50to 75 as measured according to ASTM-D2240; and a cover formed over theboundary layer, the cover composed of a fast chemical reaction aliphaticpolyurethane material formed from reactants comprising apolytetramethylene ether glycol terminated 4,4′-diphenylmethanediisocyanate polyurethane prepolymer and a polyol, wherein the aliphaticpolyurethane material has a Shore D hardness ranging from 30 to 60 asmeasured according to ASTM-D2240, a thickness ranging from 0.015 inch to0.044 inch, and an aerodynamic surface geometry thereon.